Siemens Gas Turbine PackageSGT5-PAC 4000F Application Overview

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Siemens Gas Turbine Packages – Serving Your Project Needs

Siemens supplies standardized and pre-engineered gas turbine packages custom-ized to match specific project needs in the form of simple cycle gas turbine power plants and combined cycle power plants.

The standard Siemens Gas Turbine Package (SGT-PAC) combines the essential mechan-ical, electrical, and control equipment to serve a variety of project scopes effectively. The SGT5-PAC 4000F is a key package for 50 Hz markets. The vital component is our advanced Siemens gas turbine SGT5-4000F.

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A Siemens Gas Turbine Package is: A cost-effective power generating system with pre-engineered and stan-dardized design and base scope of supply, with interconnecting piping and wiring pre-assembled to a large degree.

Flexible in design and scope thanks to pre-engineered options to meet project- and site-specific conditions, capable of increasing the operating flexibility and performance of an existing power generating system. These options can replace or add systems to the base scope.

Focused on the core equipment of a self-contained power generating system for power plants with gas turbines, it consists of gas turbine and electrical

generator as well as all the systems required for the safe and reliable oper-ation of these components: air intake system, exhaust gas system, electrical systems, instrumentation and control, generator excitation system, start-up system, and such major auxiliaries as the fuel system and lube oil system.

The development of this package stems from the requirements of the utility industry for low initial cost and a rapid and reliable on-line generation system. It is equally well-suited to meet the requirements of industrial users. Heat recovery applications include combined cycle, repowering, and cogeneration in a wide range of environments and requirements.

The SGT5-PAC 4000F is used for Generation of electrical power Combined heat and power Simple cycle gas turbine power plants Multi-shaft combined cycle power plants

operated in

Base load service Intermediate load service Peak load service

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Design Features and Arrangement

The design of the Siemens Gas Turbine Package represents over 50 years of experience in gas turbine technology and power plant design, resulting in a reliable self-contained electric power generating system.

The SGT5-PAC 4000F scope of supply represents the core equipment for a power plant equipped with gas turbines:

Gas turbine Electrical generator Air intake system Exhaust gas system Start-up system Major auxiliary system Instrumentation and control Electrical systems Power control center Enclosures Fire protection Generator systems

To minimize field assembly and the need for piping fabrication during construction, Siemens utilizes a packaging and piping concept whenever possible. Moreover, subsystems have been grouped and in-stalled in auxiliary packages.

SGT5-PAC 4000F design with the filter-house in top position

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Performance Data

Siemens SGT5–PAC 4000F Gas Turbine Package and Combined Cycle Plant

The performance data chart illustrates the application range of the Siemens SGT5-PAC 4000F Gas Turbine Package and the multi-shaft combined cycle plant as a typical application of the package.

SGT5-PAC 4000F SCC5-4000F 2x1 (multishaft)

Net power output (MW) 288 848

Net efficiency (%) 39.5 58.5

Net heat rate (kJ/kWh) 9,114 6,158

Net heat rate (Btu/kWh) 8,638 5,836

Exhaust temperature (°C/°F) 580/1,075

Exhaust mass flow (kg/s) 688

Exhaust mass flow (lb/s) 1,516

Generator type Air-cooled

Data at ISO ambient conditions

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Customer Benefits due to Extended Fleet Experience

A Siemens Gas Turbine Package is de-signed to meet customer requirements economically and flexibly. It is a cost-effective power generating system with standardized base design and base scope of supply with interconnecting piping largely pre-assembled.

Reliable project implementation with high product quality through standardization of design with pre-defined interfaces to the overall power plant and use of proven components.

High reliability through robust component and system designs and implementation of large fleet operating experience (total gas turbine fleet experience: > 1,240 units, > 220 GW, > 28 Million operating hours.

High availability through service-friendly components and optional diagnostic service.

Fuel cost savings through high component efficiencies and short start-up times.

Environmental friendlinessthrough low emissions and high efficiencies.

High operating flexibilitythrough use of online-change to different fuels and through excellent start-up and part load operating capabilities.

Flexibility to match customer- and site-specific needs through pre-defined options that can be changed or added to the base scope.

Fast construction times through shipment of pre-assembled system to site.

Compact plant sizethrough small-footprint arrangement of systems.

World-wide experienceThe SGT5-4000F has been in service since 1997. Over 190 engines of this advanced gas turbine family are in operation, and over 65 are on order. More than 4,727,000 (as of Aug 2009) cumulative operating hours and a fleet reliability exceeding 99 % have been achieved.

Siemens Simple Cycle ApplicationsThe SGT5-PAC 4000F is a self-contained electric power generating system suitable for simple cycle base load, intermediate load and peaking applications. Features proven in previous designs have been incorporated into the SSC5-4000F power plant. These include

Factory assembled fuel, auxiliary, mechanical, and electrical packages

Enclosures for turbine and auxiliary packages

A microprocessor-based control system A starting frequency converter system

Siemens Combined Cycle ApplicationsSiemens has more than three decades of experience in combined cycle plant design. That is why Siemens Combined Cycle Plants (SCC) affiliates the economi-cal benefits of a pre-engineered power plant design with outstanding flexibility through a wide range of options. Single as well as multi-shaft configurations are available.

The current SCC5-4000F Siemens Combined Cycle Plants incorporate the vast expertise and experience gained from many previous design accomplish-ments. The SCC5-4000F family is dimen-sioned to meet the various base and cycle load requirements of utilities, independent power producers, industrial users, and merchant plant operators. The develop-ment of these designs allows for cost-effective plants with minimum project-specific engineering.

87 m

60 m

43 m

30 m

(Gas turbine package layout for a typical 2x1 multi-shaft arrangement)

Typical plant layout for single-unit gas turbine package

6b

6a

7

5

5

3a3b

2a 2b

1

2d2c 8

4a 4b

9a 9b 9b

= options

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Plant Arrangement Diagram

Plant arrangements and s ystems configuration are illustrated in the chart above.

Siemens Gas Turbine Package SGT5-PAC 4000F in a multi-shaft combined cycle power plant

1 Gas Turbine2a Auxiliary Systems Module for Fuel Gas, Hydraulic Oil, Instrument Air, Lube Oil2b Auxiliary Systems Module for Fuel Oil, Purge Water, NO

X Water

2c Compressor Cleaning Skid2d Compressor Dehumidifier Skid3a Air Intake Filter House (envelope is shown schematically)3b Air Intake Duct4a Exhaust Gas Diffuser4b Stack or Bypass Stack with Diverter Damper5 Power Control Center with Electrical and I&C Equipment6a Low Voltage Transformer for Static Excitation Equipment6b Low Voltage Transformer for Starting Frequency Converter7 Electrical Generator8 CO

2 Fire Protection

9a Lube Oil Fin-Fan Cooler9b Generator Fin-Fan Cooler

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Technical Data

In the following table data are provided for planning purposes.

SGT5-4000F Gas Turbine

Compressor

Type Disk-type hollow shaft

Number of Stages 15

Rotor Speed 3,000 rpm

Pressure Ratio 18:1

Inlet Guide Vanes One row variable

Combustion System

Combustors

Type 1 ring combustor system

Configuration Annular

Fuel Gaseous and liquid

Number 24

Fuel Pressure Range

Natural Gas 27 bar–33 bar; Nominal @ gas turbine; Filter inlet flange

Turbine

Number of Stages 4

Number of Cooled Stages 3

Bearings

Journal Bearing

Type Tilting pad

Quantity 1

Thrust Bearing Drive end

Number 1

Drive

Generator coupled to cold end of turbine via intermediate shaft

SGen5-1000A Generator

Generator rating @ 40°C air inlet temperature, TEWAC

kVA 334,000

kW 283,900

P.F. 0.85

Voltage (Volts) line-to-line

20,000

Calculated short circuit ratio

0.49

Speed (rpm) 3,000

Frequency (Hz) 50

Line current (Amps) 9,641

Altitude (meters) Sea level

Insulation

Class of insulation Stator-class – F with class B temperature riseField-class – F with class B temperature rise

Weights and Dimensions

Shown below is a typical list of the major pieces of equipment along with their approximate nominal shipping weights and nominal dimensions

Item Length Width Height Weight Remarks

Gas Turbine

SGT5-PAC 4000F Gas Turbine 10.8 m 5.2 m 4.8 m 312,000 kg

Auxiliary Systems

Module for Fuel Gas Operation 11.5 m 3.3 m 3.8 m 20,000 kg

Module for Fuel Oil Operation 9.5 m 3.3 m 3.2 m 24,000 kg

Compressor Cleaning System

Base Version 1.9 m 1.1 m 1.6 m 850 kg

Advanced Cleaning System 2.7 m 2.0 m 2.2 m 1,500 kg

Air Intake System

Filterhouse 14 m 18 m 11 m 120,000 kg

Silencer * 9.5 m 7 m *

Duct 9.5 m 2.2 m 18 m 50,000 kg

Generator

SGen5-1000A Generator

Assembled (with enclosure) 14.11 m 8.63 m 5.94 m 359,000 kg

Shipping 13 m 4.6 m 4.4 m 318,000 kg

Power Control Center 12.28 m 3.64 m 3.33 m 22,000 kg

(*= project-specific)

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SGT5-4000F

1 Casing Horizontally split

2 Supports Fixed at compressor end Flexible at turbine end

3 Rotor Disk-type hollow shaft Combined thrust and journal bearing at compressor end

Journal bearing at turbine end Compressor and turbine disks interlocked via Hirth serrations

Compressor and turbine disks axially fixed via one central tie bolt

4 Compressor 15-Stage axial Variable-pitch inlet guide vanes

5 Combustion Annular chamber with ceramic and metallic heat shields

24 hybrid burners Dry low-NO

X technology

Operation with gaseous and liquid fuels

6 Turbine 4-Stage Thermal barrier blade coatings Convection and impingement cooling of blade interior

Film cooling of blade airfoil surface

7 Exhaust Axial flow

8 Generator coupling At cold end drive

1

6

5

4

8

2

3

7

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Auxiliary Systems

Fuel Gas fuel system supplies gaseous fuel with adequate mass flow to the gas turbine.

Fuel oil system as an option supplies liquid fuel with adequate mass flow to the gas turbine.

Optionally, a dual-fuel system provides highest fuel flexibility.

Rotor turning Turning device – the gas turbine rotor is rotated at low speed, for start-up, shutdown, and extended standstills.

Hydraulic Clearance Optimization The HCO (Hydraulic Clearance Optimization) power unit, supplies hydraulic oil for shifting the gas turbine rotor into the best-perfor-mance position with minimized clearances on the turbine side.

Cleaning A mobile compressor cleaning system supplies water for the compressor wash procedure to maintain high compressor efficiency.

Start-up Starting frequency converter (SFC) for static start-up.

Valve actuation A hydraulic oil system provides high-pressure hydraulic oil to operate the control and emergency stop valves of the fuel systems and NO

X water

system. Instrument air system for the supply of compressed air to operate the pneumatic actuators (e.g., blow-off valves).

Lubrication Lube oil system – supplies lubrication oil to the gas turbine, the generator, and the HCO power unit and supplies lifting oil to the gas turbine, the generator, and the hydraulic-type rotor turning device.

MAir filter ExhaustAirintake

Gas turbine

CompressorCleaning sprayNozzle system

Air filter ExhauststackAir

intake

Gas turbine

Evaporativecooling*

* option

Filter house

Gas turbine

Compressor

Air

Filter system

– Two-stage static filter

– Self-cleaning pulse filter (optional)

Inlet air cooling

Inlet air cooling provides more powerwhen needed:

– under hot and dry ambient conditions

– at times of high power demand

Air anti-icing

The anti-icing system avoidsice effects under very coldambient conditions and thusavoids pressure losses

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Air Intake System

Functions Guiding and filtering of ambient air to the gas turbine for reliable operation

Reducing noise from the gas turbine compressor to permissible levels

System scope Filter house with filter system Air intake duct with silencer

Design Top inlet air intake: the filter house is located above the generator and inlet duct and extends vertically to the gas turbine

House configuration: the support structure is supplied with existing building structure (civil scope)

Compressor cleaning spray nozzle system

Filter Systems: static filter as standard, pulse filter as an option

Anti-icing system can be provided Inlet air cooling systems on request

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Exhaust Gas System Enclosures

Functions – Exhaust system The system guides exhaust gas from the gas turbine via the diffuser to the stack of a gas turbine plant, or to the heat recovery steam generator of a combined cycle plant. Gas turbine availability can be increased with a diverter and bypass stack for com-bined-cycle power plants.

At the same time, the system reduces noise from the gas turbine to permissible levels.

System scope Exhaust diffuser Exhaust stack for simple cycle plants as an option for simple cycle applications

Diverter damper with bypass stack for combined cycle plants as an option for combined cycle applications

FunctionsIndoor enclosures:

Optimum noise protection at indoor installation in the turbine building

Delineation of hazardous areas

Containment of fire suppression agent

Weather enclosures are available on request:Noise and weather protection for outdoor installation

System scopeEnclosures when applicable with:

Ventilation system Fire detection system Fire fighting system Gas detection system

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Electrical and Control System

Functions – Electrical system Energy supply for package equipment Generator protection, excitation, and static start-up equipment

System scope AC/DC low-voltage switchgear and motor control centers for gas turbine consumers

Uninteruptable power supplies (batteries, chargers, DC/DC-converters) for gasturbine consumers

Generator protection, synchronization equipment, measurement of electrical values

Power control center (standard) to accommodate the electrical and instrumentation and control equip-ment

Static excitation system for the electrical generator

Starting frequency converter for gas turbine start-up

Low voltage transformers for the static excitation equipment and starting the frequency converter

Functions – SPPA-T3000 Control system Open loop control: step sequences for start-up and shutdown, drive control

Closed loop control: fuel valves, compressor

Inlet guide vane variation Protection: engine protection, failsafe protection circuits

Operation and monitoring: human-machine-interface

System scope and functions Operating and monitoring of the plant Automation (basic automation, turbine control, failsafe protection)

Engineering of the instrumentation and control system

Diagnostics on the instrumentation and control system

Diagnostics on the package Bus systems

Benefits Single user interface for all functions, from anywhere

Intuitive links throughout the entire system

Speeds up the work-flow

SPPA-T3000 Control System

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Power Control Center

Features of the Power Control CenterThe features of the Power Control Center (PCC) modules make them equivalent to a conventional housing/building:

The degree of protection of the switchgear rooms is IP 54.

The switchgear room temperature in the PCC modules is controlled between 10 °C and 35 °C by air-conditioning units. At least one redundant air-conditioning aggregate is provided.

The air is cleaned by a filter. The sealed construction prevents any ingress of moisture or dust by leakage. In addition, the heat exchangers dehydrate the replacement air so that condensation inside the modules cannot occur.

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SGen5-1000A

One generator assembly consisting of the following components is delivered to the site:

Bedplate Spring mounted stator Bearing pedestals Rotor with shrunk-on collector Stator inner enclosure

At the site, an outer enclosure is erected around the generator that includes coolers, current transformers, and neutral grounding equipment.

The SGen5-1000A air-cooled generator features:

165 – 350 MVA range (at 40 °C cold gas condition)

World class efficiency with low maintenance design

Multi-zone, indirectly cooled stator windings

Roebelled stator windings with brazed solid end connections

Radially ventilated stator core attached to bedplate

Global Vacuum Pressure Impregnated (GVPI) stator core and stator winding

Core suspended on two axial springs Radially ventilated and cooled rotor winding

Two low pressure “push” fans mounted at each end of the rotor

Weather and sound proof outer generator enclosure

Coolers mounted on foundation beside bedplate and inside outer enclosure for a TEWAC (Totally Enclosed Water to Air-cooled) generator

Overhung collector and brush holders bedplateThe stator bedplate is a heavy steel fabrication, which supports the stator core and windings, bearing pedestals, rotor assembly excitation casing, and the inner enclosure. The bedplate rests on leveling devices (fixators) affixed to the foundation and is secured with foundation bolts and axial and transverse anchors. Features for lifting and suitable jacking points for alignment to the turbine are also provided.

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Power Diagnostics

Power Diagnostics® ServicesRemote online monitoring of entire power plants or vital power plant components via Siemens Power Diagnostics Services is a key to mitigate risk for long-term service contracts. Based on several Power Diagnostics Centers worldwide Siemens provides the Service of daily Online Remote Diagnostics exclusively for Customers with long-term service agreements. Currently more than 300 advanced frame gas turbines, as well as heat recovery boilers, steam turbines and generators are monitored via those centers by Siemens experts to ensure the most trouble-free operation.

The WIN_TS diagnostic system including a broadband connection for unlimited remote access has to be installed for online remote diagnostic services. The connection of a phone line exclusively assigned for the use of WIN_TS or an internet link is required as a contractual obligation of the customer already before commissioning starts.

BenefitsDuring plant operation, online remote diagnostics provide the following advantages:

Plants can be monitored effectively by Power Diagnostics Centers and OEM experts, e.g., of forced outages or emerging damages by detection of possible engine failures before they occur can be avoided

Risk mitigation through service support for O&M and LTP during gas turbine life cycle, e.g., condition based outage planning by Siemens with the strong support of Siemens experts from all disciplines

Detailed information on plant’s history, long term trends, and optimization of operational reliability and availability

It also supports OEM’s engineering staff in develop-ing their modernization and upgrade programs as well as Performance Enhancement Programs and optimi-zation of Operational Reliability and Availability Programs

Your benefits include: Improved performance in terms of availability, reliability, efficiency and flexibility

Reduced maintenance costs by extended maintenance intervals, condition based maintenance and shorter outages

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Service and Support

Corrective & preventive maintenanceExpecting a reliable high output from your plant, we set the goal to help you cut downtimes to a minimum. With our diagnostic services we can even identify faults before they become failures. From installation and commissioning, sched-uled overhauls, on-site/factory repairs to spare parts, we are ready to serve you. With our remote monitoring & diagnostics capabilities we can help you instantly. Our global team of more than 3,000 highly qualified Siemens service specialists is dedicated to providing sound, reliable and continuing support. Anywhere, any time.

Service agreementsTo plan well ahead a service agreement for your plant can best support your long- term goals. We can help proactively boost your plant’s performance through various service options. From operating plant service agreements to full-scope operation, maintenance contracts and remote moni-toring – Siemens Energy’s service solu-tions can be adapted to your exact needs: scheduled inspections, preventive main-tenance, remote monitoring, replace-ment parts programs and incentives. In addition, we offer on-site operation & maintenance contracts for power plants.

Benefits include: Optimized return on investment Optimized performance Optimized strategic planning for operating assets

Reduced maintenance costs

Training & Consulting Siemens Power Academy (SPA)Training courses and programs designed to provide you essential knowledge of equipment and systems ensure your safe, reliable operation and routine mainte-nance for your assets.

SGT5-4000F Steam Production

Steam pressure [bar]

150

Steam production [kg/s]

538 °C

482 °C

145

140

135

130

125

120

115

110

105

100

95

905 15 25 35 45 55 65 75

Saturated

316 °C

371 °C

427 °C

260 °C204 °C

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Cogeneration or Combined Heat and Power

General descriptionOwners and operators of industrial and commercial facilities are actively looking for ways to use energy more efficiently. One option is cogeneration, also known as combined heat and power (CHP). Cogeneration/CHP consists of simulta-neous production of electricity and useful heat from the same fuel or energy. The owner of a SGT5-PAC 4000F cogen system can use it to produce their own electricity, produce electricity for sale to others, or use the excess (waste) heat for process steam, hot water heating, space heating and other thermal needs.

The excess heat also can be used to produce steam that can drive a steam turbine-generator to produce additional electricity. A SGT5-PAC 4000F-based cogen system can be designed, with the addition of the appropriate heat recovery boiler

and steam turbine-generator, to use the maximum amount of available energy. The steam turbine can be selected from extraction, condensing or backpressure styles to best match the customer’s pro-cess steam and electricity requirements.

Steam production calculationThe figure above shows the typical steam production capability of the SGT5-PAC 4000F for a range of steam pressures and temperatures. The referenced results are for

Base load operation at sea level, 15 °C compressor inlet temperature, 60 % relative humidity of the air and Natural gas fuel.

The heat recovery system chosen has one pressure level, a 8.3 K pinch point, 5.5 K approach temperature and no supplementary firing. Although steam production varies depending on site conditions and gas turbine loading, the figure provides an estimate of what can be achieved with a SGT5-PAC 4000F.

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References

Panglima, MalaysiaPanglima Power Sdn Bhd operates the combined cycle power plant with a multi-shaft 2 x 1 unit that has a total capacity of 780 MW, including two gas turbine packages SGT5-PAC 4000F.

Hamm-Uentrop, GermanyTrianel Power Kraftwerk Hamm-Uentrop GmbH & Co. KG operates the combined cycle power plant with a total capacity of 850 MW. Included in the scope are two gas turbine packages SGT5-PAC 4000F.

Al Taweelah, United Arab EmiratesAl Taweelah A2 is the first IPP project in the Middle East. The project with an output of 780 MW represents the first combination of a combined cycle power plant with a desalination plant. The scope included three gas turbine packages SGT5-PAC 4000F and two steam turbines.

Antalya, Turkey The Ali Metin Kazanci Power Plant in Antalya, Turkey consists of two gas turbine packages SGT5-PAC 4000F. The power plant is built and operated by the Turkish company AKSA and covers a major part of the high energy demand in Antalya – one of the major tourist areas in Turkey. The 520 MW Open Cycle plant was built by AKSA in world record time. In a second phase this plant will be completed by AKSA to an 780 MW Combined Cycle Power Plant with one Siemens Steam Turbine Package SST-5000.

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Subject to change without prior notice.The information in this document contains generaldescriptions of the technical options available, whichmay not apply in all cases. The required technicaloptions should therefore be specified in the contract.

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